?? In-depth analysis of the seven failure modes of high-frequency transformers | Engineers must read the guide ??

1. External Appearance Defects

Transformers undergo complex manufacturing processes. During production, the core and frame can suffer collisions during transport or processing, leading to cosmetic damage.

• Main Causes: Collisions or impacts on the core and frame during processing; product drops, etc.
• Impact: Although individual unit tests may not show parameter differences, when assembled into the final product, these damages can seriously affect overall performance. Typically, the damaged area should not exceed 3% of the total product surface.
• Preventive Measures: Enhance work management and operator training to ensure skilled handling. ??♂?

2. Voltage Withstand (Dielectric Strength) Issues

Voltage withstanding problems are one of the common electrical failures in transformers.

• Main Causes: Damaged tape insulation, improper wrapping, or a broken frame can lead to insufficient insulation and inadequate creepage distances.
• Preventive Measures: Increase the spacing between components and enhance the performance of insulation materials to resolve these issues. ?

3. Inductance Issues

Inductance problems typically arise from:

• Main Causes: Insufficient air gap design, improper core assembly, or the absence of proper adhesive application.
• Testing Methods: Semi-finished product testing can quickly detect any anomalies in inductance, ensuring products meet the required standards before shipment.
• Importance: In practical operation, poor inductance can affect the overall performance and stability of the transformer. ??

4. Leakage Inductance Issues

Leakage inductance primarily develops during the winding process:

• Main Causes: Improper winding arrangement; designers often use sandwich winding or add shielding to reduce leakage inductance.
• Notes: In some double-slot designs, a certain degree of leakage inductance is intentionally used to achieve specific functional adjustments, which is closely related to the spacing and number of turns between the primary and secondary windings. ??

5. Winding Turns Defects

Problems with the number of turns are generally related to the calibration of automatic winding machines:

• Main Causes: Inadequate control by semi-automatic or fully automatic winding equipment.
• Testing: Detect these defects during the initial inspection of products to prevent mass production issues. ??

6. Inter-layer Short Circuit

Inter-layer short circuits are often due to process-related issues:

• Main Causes: When multi-strand or enameled wires are wound in multiple layers without proper tape insulation between them, short circuits can occur, sometimes accompanied by layer separation problems.
• Key Point: The matching of each winding layer’s width with the tape width is crucial. ??

7. Resistance Issues

Resistance-related problems rarely occur unless:

• Main Causes: Incorrect wire gauge selection, improper soldering of windings, or open circuits in the winding.
• Comprehensive Analysis: When multiple failure modes occur simultaneously, combining electrical parameter tests with product teardown is necessary to identify the root cause. ??

Summary and Outlook ??

Transformers can fail in many ways, and any issue in a single stage can affect the performance of the final product. In production, it is crucial not only to have a refined process but also to enforce strict quality management and timely testing feedback to ensure every stage meets the standards. Through this detailed analysis, we hope engineers and technicians will better understand the critical quality indicators and provide a solid foundation for improving overall system performance. ??

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